Tiling production of packaging materials

ABSTRACT

The present invention extends to methods, machines, systems, and computer program products for producing multiple packaging products in a tiled configuration within source production material, enabling production of multiple packaging products in parallel. Embodiments include accessing item data identifying items that are to be packaged, and determining packaging requirements for each item. A pair of box sizes that satisfy the packaging requirements are selected for tiled production. A packaging production machine to be used is also selected. Selection of the box sizes and/or the packaging production machine is based on a collective analysis of packaging requirements, packing system characteristics, and packaging machine characteristics. Based on the collective analysis, it is determined how to allocate box production to the production machine, and the pair of box sizes is matched to the production machine. Box production instructions are generated and sent to the packaging production machine.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of PCT Application No.PCT/US2012/047562, filed Jul. 20, 2012, entitled “Tiling Production ofPackaging Materials”, which claims the benefit of and priority to U.S.Provisional Application No. 61/510,894, filed on Jul. 22, 2011, entitled“Tiling Production of Packaging Materials”, each of which isincorporated by reference herein in its entirety.

This application also claims the benefit of and priority to U.S.Provisional Application No. 61/754,462, filed Jan. 18, 2013, entitled“Tiling Production of Packaging Materials”, which is incorporated byreference herein in its entirety.

BACKGROUND 1. Background and Relevant Art

With the increasing availability of merchandise, products, and otheritems not only locally, but also through a global market, the needs toproperly package such materials for shipment and delivery have neverbeen more important. Fortunately, available packaging systems can now beused to produce virtually any style of product packaging from packagingmaterials such as corrugated cardboard.

Perhaps the single biggest factor in producing packaging for a productis that the packaging be designed to fit the contained product asprecisely as possible. With a more precise fit, the contained item orproduct not only is less likely to be damaged, but the need for innerpackaging is also reduced and possibly eliminated. In particular, whenpackaging materials such as corrugated cardboard are used to create abox or other packaging design, the materials are creased and folded asnear to a right angle possible. Creasing and folding at right anglesincreases strength characteristics of the packaging materials(essentially exponentially), thereby giving a resulting box acorrespondingly increased resistance to damage when stacked.

Many different styles of boxes may, however, be produced to satisfyspecified dimensional constraints. Each of the different styles of boxesmay have different advantages or disadvantages. For instance, somestyles of boxes may be more aesthetically pleasing while others mayprovide greater protective features. Still other boxes styles may bemore rapidly produced and/or assembled, while others may require lessmaterial for production, or less material for the assembly, closing, orother manipulation of the box template.

Because of the vast number of boxes types and other packaging materialsthat may be produced, each with their own positive and negativefeatures, it may be very difficult for a person unfamiliar with aparticular style of box to identify when certain styles or combinationsof styles may be used. Even if information about the types of availablestyles is provided, it can be difficult and/or time consuming for theperson producing or assembling a box to review each available option andselect a preferred option. Moreover, in some circumstances, real timeproduction factors may influence when a particular box should be used.For example, if there is a production backlog, it may be desirable toincrease throughput by producing boxes that have lower production times,even if the produced boxes have lower aesthetic or protective abilities,or require more production or assembly materials. In other cases, thereal-time information may indicate that there is excess capacity suchthat other considerations are given higher priority.

BRIEF SUMMARY

The present invention extends to methods, machines, systems, andcomputer program products for optimizing production of packagingproducts by producing tiled box templates.

In one or more embodiments, a computer system accesses item dataidentifying items that are to be packaged, and determines packagingrequirements for each of the items. The computer system then selects apair of box sizes for tiled production at a packaging productionmachine. The pair of box sizes, which satisfy the packaging requirementsfor the identified items, include a first box size for packaging a firstitem and a second box size for packaging a second item.

The computer system also selects the package production machine, fromamong one or more packaging production machines, by (i) collectivelyanalyzing the packaging requirements for each item, the packing systemcharacteristics, and the packaging machine characteristics for each ofthe one or more packaging production machines; and (ii) based on thecollective analysis, determines how to allocate box production to theone or more packaging production machines for a period of time. The pairof box sizes is then matched to the packaging production machine.

After selecting the pair of box sizes, the computer system generates boxproduction instructions which indicate how to tile production of a boxof the first box size with a box of the second box size at the packagingproduction machine. The computer system then sends the box productioninstructions to the packaging production machine.

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

Additional features and advantages of the invention will be set forth inthe description which follows, and in part will be obvious from thedescription, or may be learned by the practice of the invention. Thefeatures and advantages of the invention may be realized and obtained bymeans of the instruments and combinations particularly pointed out inthe appended claims. These and other features of the present inventionwill become more fully apparent from the following description andappended claims, or may be learned by the practice of the invention asset forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and otheradvantages and features of the invention can be obtained, a moreparticular description of the invention briefly described above will berendered by reference to specific embodiments thereof which areillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered to be limiting of its scope, the invention will bedescribed and explained with additional specificity and detail throughthe use of the accompanying drawings in which:

FIG. 1 illustrates an example production architecture that facilitatesoptimizing production of packaging products.

FIG. 2 illustrates a flow chart of an example method for optimizingproduction of packaging products.

FIG. 3 illustrates an example packaging information table.

FIG. 4 illustrates an example user-interface for accepting packagingproduction information.

FIG. 5A illustrates an example packaging materials table.

FIG. 5B illustrates an example machine data table.

FIG. 6 illustrates a flow chart of an example method for selecting adesign for a packaging product.

FIG. 7 illustrates an example user interface for presenting packagingdesigns.

FIG. 8 illustrates an example a production track configured to producetiled templates within source production material.

FIG. 9 illustrates a flow chart of an example method for tilingproduction for a pair of boxes.

DETAILED DESCRIPTION

The present invention extends to methods, machines, systems, andcomputer program products for optimizing production of packagingproducts by producing tiled box templates.

In one or more embodiments, a computer system accesses item dataidentifying items that are to be packaged, and determines packagingrequirements for each of the items. The computer system then selects apair of box sizes for tiled production at a packaging productionmachine. The pair of box sizes, which satisfy the packaging requirementsfor the identified items, include a first box size for packaging a firstitem and a second box size for packaging a second item.

The computer system also selects the package production machine, fromamong one or more packaging production machines, by (i) collectivelyanalyzing the packaging requirements for each item, the packing systemcharacteristics, and the packaging machine characteristics for each ofthe one or more packaging production machines; and (ii) based on thecollective analysis, determines how to allocate box production to theone or more packaging production machines for a period of time. The pairof box sizes is then matched to the packaging production machine.

After selecting the pair of box sizes, the computer system generates boxproduction instructions which indicate how to tile production of a boxof the first box size with a box of the second box size at the packagingproduction machine. The computer system then sends the box productioninstructions to the packaging production machine.

Embodiments of the present invention may comprise or utilize a specialpurpose or general-purpose computer including computer hardware, suchas, for example, one or more processors and system memory, as discussedin greater detail below. Embodiments within the scope of the presentinvention also include physical and other computer-readable media forcarrying or storing computer-executable instructions and/or datastructures. Such computer-readable media can be any available media thatcan be accessed by a general purpose or special purpose computer system.Computer-readable media that store computer-executable instructions arecomputer storage media (devices). Computer-readable media that carrycomputer-executable instructions are transmission media. Thus, by way ofexample, and not limitation, embodiments of the invention can compriseat least two distinctly different kinds of computer-readable media:computer storage media (devices) and transmission media.

Computer storage media (devices) includes RAM, ROM, EEPROM, CD-ROM,solid state drives (“SSDs”) (e.g., based on RAM), Flash memory,phase-change memory (“PCM”), other types of memory, other optical diskstorage, magnetic disk storage or other magnetic storage devices, or anyother medium which can be used to store desired program code means inthe form of computer-executable instructions or data structures andwhich can be accessed by a general purpose or special purpose computer.

A “network” is defined as one or more data links that enable thetransport of electronic data between computer systems and/or modulesand/or other electronic devices. When information is transferred orprovided over a network or another communications connection (eitherhardwired, wireless, or a combination of hardwired or wireless) to acomputer, the computer properly views the connection as a transmissionmedium. Transmissions media can include a network and/or data linkswhich can be used to carry desired program code means in the form ofcomputer-executable instructions or data structures and which can beaccessed by a general purpose or special purpose computer. Combinationsof the above should also be included within the scope ofcomputer-readable media.

Further, upon reaching various computer system components, program codemeans in the form of computer-executable instructions or data structurescan be transferred automatically from transmission media to computerstorage media (devices) (or vice versa). For example,computer-executable instructions or data structures received over anetwork or data link can be buffered in RAM within a network interfacemodule (e.g., a “NIC”), and then eventually transferred to computersystem RAM and/or to less volatile computer storage media (devices) at acomputer system. Thus, it should be understood that computer storagemedia (devices) can be included in computer system components that also(or even primarily) utilize transmission media.

Computer-executable instructions comprise, for example, instructions anddata which, when executed at a processor, cause a general purposecomputer, special purpose computer, or special purpose processing deviceto perform a certain function or group of functions. The computerexecutable instructions may be, for example, binaries, intermediateformat instructions such as assembly language, or even source code.Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the described features or acts described above.Rather, the described features and acts are disclosed as example formsof implementing the claims.

Those skilled in the art will appreciate that the invention may bepracticed in network computing environments with many types of computersystem configurations, including, personal computers, desktop computers,laptop computers, message processors, hand-held devices, multi-processorsystems, microprocessor-based or programmable consumer electronics,network PCs, minicomputers, mainframe computers, mobile telephones,PDAs, pagers, routers, switches, package production machines, and thelike. The invention may also be practiced in distributed systemenvironments where local and remote computer systems, which are linked(either by hardwired data links, wireless data links, or by acombination of hardwired and wireless data links) through a network,both perform tasks. In a distributed system environment, program modulesmay be located in both local and remote memory storage devices.

Embodiments of the invention can efficiently and automatically determineand select optimal packaging designs to produce packaging products, suchas, for example, box templates. Determining and selecting packagingdesigns can be based on packaging product information and definedpackaging designs, and in some embodiments can also be based one or moreof: production machine data, packaging material data, or productionenvironment real-time considerations. Packaging production machines canthen be instructed to produce packaging products in accordance withselected packaging designs.

Embodiments of the invention can also determine an optimized arrangementof box templates within source packaging material which can, in turn,optimize one or both of the rate of box production or the efficient useof the source packaging material. For example, embodiments of theinvention can tile box templates within the source packaging material,enabling a single production device to produce multiple boxes inparallel, while also minimizing waste. Optimizing the arrangement of boxtemplates within source packaging material can occur in connection withdetermining and selecting optimal packaging designs, or can occur as aseparate process.

FIG. 1 illustrates an example production architecture 100 thatfacilitates optimizing production of packaging products. Referring toFIG. 1, production architecture 100 includes packaging productionmachine 102, computer system 104, and data store 106. Each of thedepicted components and machines is connected to one another over (or ispart of) a network, such as, for example, a Local Area Network (“LAN”),a Wide Area Network (“WAN”), or even the Internet. Accordingly, each ofthe depicted computer systems as well as any other connected computersystems, machines, and their components, can create message related dataand exchange message related data (e.g., Internet Protocol (“IP”)datagrams and other higher layer protocols that utilize IP datagrams,such as, Transmission Control Protocol (“TCP”), Hypertext TransferProtocol (“HTTP”), Simple Mail Transfer Protocol (“SMTP”), etc.) overthe network.

Packaging production machine 102 includes one or more production tracks,such as the depicted production tracks 102A, 102B, and 102C. Each ofproduction tracks 102A, 102B, and 102C can be loaded with raw packagingmaterials, such as, for example, fanfold or rolled corrugated board. Asdepicted, each of production tracks 102A, 102B, and 102C, has adifferent maximum width for the raw packaging materials. As productiontracks 102A, 102B, and 102C produce packaging products (e.g., boxtemplates), packaging product machine 102 can maintain a local store ofusage data. Packaging production machine 102 can include a NIC fornetwork communication. From time to time or at desired intervals,packaging production machine 102 can communicate usage data from thelocal store to computer system 104 and/or data store 106 using the NIC.The vertical ellipsis above and below packaging production machine 102represent that one or more additional packaging production machines canbe included in production architecture 100.

Generally, data store 106 can store different types of information foroptimizing the production of packaging products. For example, data store106 can store information for one or more packaging production machines,such as, for example, packaging production machine 102. Storedinformation for packaging production machines can include packagingproduction machine types, cost to run packaging production machines, rawpackaging material types available at packaging production machines,design groups used to optimize packaging production at the packagingproduction machines, etc. As depicted in production architecture 100,data store 106 more specifically includes packaging design table 301,packaging materials table 501, and machine data table 502.

Computer system 104 includes optimization module 112. Generally,optimization module 112 is configured to optimize production ofpackaging products. In some embodiments, optimization module 112includes real-time packaging product design functionality. When apackaging product is to be produced, optimization module 112 can referto data in data store 106 to determine how to optimize production of thepackaging product. When optimization is determined, optimization module112 can send instructions to a packaging production machine. Theinstructions instruct the packaging production machine to produce apackaging product in accordance with the determined optimization.

In some embodiments, computer system 104 and/or packaging productionmachine 102 utilize all or some of the information from data store 106to optimize which types and/or sizes of packaging templates are to bemade by packaging production machine 102. In some embodiments, computersystem 104 and/or packaging production machine 102 also optimize whichproduction track should be used to produce a packaging product from rawpackaging materials.

Further, although packaging production machine 102, computer system 104,and data store 106 are depicted separately, components and data depictedat production machine 102, computer system 104, and data store 106 canbe combined. For example, it may be that computer system 104 isphysically integrated into packaging production machine 102. Similarly,data store 106 can be physically integrated into computer system 104and/or packaging production machine 102.

In some embodiments, a packaging product is a box template. The boxtemplate can be further manipulated (e.g., folded and edges connectedtogether) to form a box. Different types of boxes or other packaging maybe used or desirable for different projects. Box size can vary based onwhat is being enclosed within the box. Other types of features may alsobe considered in determining what type and/or size box is desired for aparticular use or application. Enclosing a heavy or fragile object may,for instance, dictate that a box of a certain type of material be used,or that a box that has improved protection characteristics (e.g., glueflap, integral corner protectors, full size flaps, etc.) be used.

Thus, as generally described, the components of production architecture100 can be used to optimize production of packaging products based onany number of different features or considerations. To facilitate theuse of production architecture 100 in identifying appropriate packagingfor an object, any of a number of different designs or types ofpackaging may be considered. Each packaging type or design may have adifferent shape, style, or other feature. For example, one box designmay have top and/or bottom flaps that are approximately half the widthof the final box. For other box designs, the top and/or bottom flaps maybe up to the full width of the box. These or other types of boxes mayalso include glue or staple flaps for assembly, have integrated cornerprotectors built into the top and/or bottom flaps, or have otherfeatures or any combination thereof.

FIG. 2 illustrates a flow chart of an example method 200 for optimizingproduction of packaging products. Method 200 will be described withrespect to the components and data of computer architecture 100. Duringthe description of method 200 reference will also be made to FIGS. 3, 4,5A, and 5B.

Method 200 includes an act of receiving packaging production informationfor producing a packaging product, the packaging production informationat least defining the size of the packaging product (act 201). Forexample, computer system 104 can receive packaging productioninformation 111. Packaging production information 111 can define thesize of a packaging product (e.g., a box). Packaging productioninformation 111 can also include other information that optimizationmodule 112 can use to determine how to optimize production of thepackaging product. For example, the other information can include aquantity of boxes to produce, a selected design group, productionconditions, available packaging production machines, production timecost, etc.

In some embodiments, packaging production information 111 is formulatedin an automated fashion at another computer system or even withinanother module of computer system 104. In other embodiments, a humanuser enters packaging production information 111 through auser-interface, for example, provided at computer system 104 or someother network location. Referring briefly to FIG. 4, user-interface 401depicts different user-interface controls for entering packagingproduction information. An operator or other user can use use-interface401 to enter box dimensions, a quantity of boxes to produce, a designgroup selection, indicate production conditions, select availableproduction machines, and indicate a production time cost. For example,through user-interface 401, a user can select design group 302 a andindicate that packaging production machine 102 is available. Packagingproduction information entered through user-interface 401 can beincluded in packaging production information 111.

Method 200 includes an act of accessing a plurality of differentpackaging designs, each of the plurality of different packaging designsindicating values for a combination of packaging productioncharacteristics, the indicated values for the combination of packagingproduction characteristics to be used when producing a packaging productin accordance with the packaging design (act 202). For example, computersystem 104 can access packaging design table 301. Referring now to FIG.3, packaging design table 301 has columns including design groups 302,design features 310, preference score 311, options 312, restrictions308, and description 314.

Design groups 302 include a number of design groups 302 a, 302 b, 302 c,302 d, 302 e, 302 f, etc. Each design group can include one or more maindesigns. For example, design group 302 a includes main designs 304. Eachmain design can relate to a specified algorithm or other design that canbe scored, evaluated, or otherwise related to other main designs in acorresponding design group.

A hierarchy can be established within the design groups. For example,main design 304 a has multiple packaging designs 306 defined therein.Each of packaging designs 306 is related to main design 304 a of whichit is a part. However, each of packaging designs 306 includes at leastone different value or different option in design features 310,preference score 311, options 312, and/or restrictions 308 thatdifferentiates it from other packaging designs 306. For example,different packaging designs 306 may relate to the same main design withlength, width, and height dimensions interchanged, added trays andseparators within a design, or to other features or aspects common to amain design.

In some embodiments, main designs 304 can correspond to different typesof boxes. For example, main design 304 a can correspond to boxes havingRegular Slotted Carton (“RSC”) designs, full flap boxes, integral cornerprotection boxes, bottom lid construction boxes with separate bottom,and lid components. Other main designs 304 correspond to other types ofpackaging designs. Each packaging design may have one or more associatedformulas that may be used to produce the design. For example, if a maindesign is used to produce a rectangular box, a formula may take adesired length, width and height for the assembled box. Based on themain design, a box template is produced. The box template can be foldedto produce the box of the particular length, width and height, and whichalso offers the other characteristics or features of the particular maindesign.

Thus, the various packaging designs 306 can be considered as sub-designswithin main design 304 a. Each of packaging designs 306 can use asimilar, or even essentially the same, formula with some variation.

When appropriate, computer system 104 can also access one or morepackaging materials table 501 and machine data table 502. Referring toFIG. 5A, packaging materials table 501 indicates aspects of one or morepackaging materials that are available within production architecture100, some of which may be available at packaging production machine 102.For example, packaging materials table 501 indicates packaging materialaspects, such as, for example, name, type, width, thickness, quantity,and cost.

Referring to FIG. 5B, machine data table 502 indicates aspects of one ormore packaging production machines in production architecture 100,including packaging production machine 102. For example, machine datatable 502 indicates packaging production machines including name,associated operational cost (e.g., relative cost for each second that isrequired to produce a packaging product), availability of differentpackaging materials, etc.

Method 200 includes an act of selecting a packaging design, from amongthe plurality of different packaging designs, for producing thepackaging product, the selection based on the suitability of theselected packaging design to produce a packaging product in accordancewith the packaging production information (act 203). For example,optimization module 112 can select packaging design 306 a based on thesuitability of packaging product design 306 a to produce a packagingproduct (e.g., a box template) in accordance with packaging productioninformation 111. The contents of packaging materials table 501 and/ormachine data table 502 can also be considered when selecting packagingdesign 306 a. Any number of different algorithms considering packagingdesign table 301 and one or more of packaging materials table 501 ormachine data table 502 can be used for packaging design selection.

In some embodiments, an algorithm processes one or more values and/oroptions from packaging design table 301 and one or more values and/oroptions from packaging materials table 501 and/or from machine datatable 502 to generate score values for different packaging designs.Based on the generated score values, optimization module 112 can selecta packaging design.

Method 200 includes an act of sending instructions to produce thepackaging product to a packaging production machine, the instructionsinstructing the packaging production machine to use available rawmaterials sufficient for the defined size and in accordance with theselected packaging design (act 204). For example, computer system 104can send production instructions 114 to packaging production machine102. Packaging production instructions 114 instruct packaging productionmachine 102 to use raw materials sufficient to create a packagingproduct of the size defined in packaging production information and tocreate the packaging product in accordance with packaging design 306 a.

Other embodiments of the invention include establishing packaginginformation and then using the established packaging information toselect a packaging design. FIG. 6 illustrates a flow chart of an examplemethod 600 for selecting a design for a packaging product. Method 600will be described with respect to FIGS. 3, 4, 5A, 5B, and 7.

Method 600 includes an act of defining design groups (act 601). Forexample, with reference to FIG. 3, design groups 302 can be defined.Design groups 302 can relate generally to sets of different weights,preferences, restrictions, and other considerations, or combinations ofthe foregoing, that a user, operator, customer, or other person orentity places on a particular design. For example, different designgroups may be designed for use with different products, different typesof products (e.g., fragile vs. non-fragile, expensive vs. inexpensive,etc.), different customers, and the like.

Method 600 includes an act of setting up a hierarchy within designgroups (act 602). For example, each design group 302 can be set up withone or more different main designs 304. Each main design 304 can relateto a particular algorithm or other design that may be scored, evaluated,or otherwise related to other main designs 304 within design group 302.Each main design 304 can also be set up with one or more packagingdesigns. For example, main design 304 a includes packaging designs 306.

Setting up a hierarchy within design grouped can include assigningvalues for one or more of design features 310, preference score 311,options 312, restrictions 308, or description 314 for each packagingdesign. Thus, each packaging design 306 is related to main design 304 a,but includes various different options. Accordingly, the variouspackaging designs 306 may be considered as sub-designs within maindesign 304 a, and can use the same formula—or essentially the sameformula—but with some variation. For example, different packagingdesigns 306 can relate to the same main design with length, width, andheight dimensions interchanged, added trays and separators within adesign, or to other features or aspects common to main design 304 a.

In some embodiments, setting up a hierarchy includes establishing maindesigns that correspond to different types of boxes. For example, someof main designs 304 may correspond to boxes having RSC designs, fullflap boxes, integral corner protection boxes, bottom lid constructionboxes with separate bottom and lid components. Other of main designs 304correspond to other types of packaging designs. Each packaging designmay have one or more associated formulas that may be used to produce thedesign. For example, if a main design is used to produce a rectangularbox, a formula may take a desired length, width and height for theassembled box, and then produce a box template that can be folded toproduce the box of the particular length, width and height, and whichalso offers the other characteristics or features of the particular maindesign.

In some embodiments, a single type of packaging may be produced by usingthe desired length, height, and width of the desired box. There are,however, up to six different combinations that may be obtained simply byvarying the length, width, and height values. Thus, if a user inputslength, height, and width values, the various packaging designs 306 mayrelate to different combinations (e.g., using the length as the height,the height as the width, and the width as the length). A user can inputthe dimensions in one way and then optimization module 112 can evaluatethe dimensions in six different combinations. For example, a box mayhave the following dimensions:

Dimension 1: 12 inches

Dimension 2: 18 inches

Dimension 3: 14 inches.

This same box may also be described in any of the following manners:

Length/Width/Height:

-   -   A: 12 in by 18 in by 14 in    -   B: 12 in by 14 in by 18 in    -   C: 18 in by 12 in by 14 in    -   D: 18 in by 14 in by 12 in    -   E: 14 in by 12 in by 18 in    -   F: 14 in by 18 in by 12 in

Ultimately, any of these combinations of the same dimensions may be usedto produce a box that has the same overall dimensions (namely 12 inchesby 18 inches by 14 inches). However, as the dimensions are input into aformula in a particular form, the size and shape of the two-dimensionaltemplate that may be folded to produce the box of the specified size maybe varied. In some cases, the width and length of the template canchange based on the particular combination of length/width/heightdimensions. Particularly where a packaging production machine has accessto a limited set of types of materials (e.g., fanfold or rolledcorrugated board of particular widths), the size of the template maymake a difference in the overall cost to produce the box. The differentdimensional combinations may also affect the amount of materials used toassemble or close the box, the time to assemble the box, the difficultyin assembling the box, and the like. For example, boxes of differentdimensions may require different amounts of glue or other adhesives,staples, strapping bands, or other materials used to prepare, erect,mark, and/or close a box.

To illustrate, entered dimensions for a first box template can be about50 inches wide and about 64 inches long. Entered dimensions for a secondbox template can be about 80 inches wide and about 40 inches long. Thus,the total area of both the first box template and the second boxtemplate are 3200 in². A packaging production machine may have access tofanfold or rolled production materials that are 55 inches wide and 100inches wide. Thus, even though the overall areas are the same, morepackaging materials may be necessary to produce the second box template.

For example, if the second box template is produced from the 100 inchwide material, 4000 in² (i.e., 100 inches by 40 inches) of productionmaterials are used to produce the second box template. If the second boxtemplate is rotated and produced from the 55 inch wide fanfold, 4400 in²(i.e., 55 inches by 80 inches) of production materials are used toproduce the second box template. In contrast, the first box template maybe produced from the 55 inch wide material, such that the total materialused is 3520 in² (i.e., 55 inches by 64 inches).

Accordingly, changing the manner in which dimensions are input toproduce a same type of box may have an impact on the box or the cost toproduce a box. Entered dimensions can also affect other aspects ofpackaging production. For example, the structural strength of a box mayalso change (e.g., by changing the length of a glue/staple flap), thedifficulty of assembly may increase, the overall aesthetic appearance ofthe box may change, or a number of other characteristics or features maychange based solely on which dimensions are used as the length, width,or height. Moreover, other changes to a main design 304 may also beaddressed within a sub-design (e.g., adding inserts or dividers to atray or within a box).

Setting up a hierarchy within design groups can also include specifyingone or more design features 310, such as, for example, aesthetics,labor, production capacity, assembly/material costs, and protection foreach packaging design. Setting up a hierarchy can also includespecifying a preference score 311 for each packaging design

Setting up a hierarchy within design groups can also include specifyingoptions 312 for each packaging design. For example, options 312 can bespecified to indicate whether a design may be rotated, mirrored, andhave multiple outputs for a particular packaging design 306 or maindesign 304. In general, rotated or mirrored versions of a main design(or of a particular packaging design) may have generally the sameoverall two-dimensional template dimensions of a corresponding design.There can advantages to a rotating a design. For example, packagingmaterials (e.g., fanfold or rolled corrugated materials) may beavailable in only certain widths. A template that is 60 inches wide by40 inches long may thus be produced by fanfold material that is 75inches wide. However, by rotating the template, the same design may beproduced using fanfold material that is 42 inches wide, thereby reducingthe overall material usage in production of the template.

For packaging designs 306 with multiple outs enabled (e.g., PD1, PD2,PD3, PD₅, and PD₇, as shown in FIG. 3), multiple templates may beproduced side-by-side (or “tiled”) within the production material. Thatis, substantially the entire width of production materials (e.g.,fanfold corrugated board) can be used to produce a plurality of (e.g.,two) packaging products (e.g., box templates) essentially or entirely inparallel. Enabling multiple outs may allow multiple identical designs tobe produced side-by-side, or may even allow different designs to beproduced side-by-side.

Tiling packaging products to produce the packaging products in parallelcan greatly increase the speed and efficiency with which packagingproducts are produced, and can help maximize utilization of limitedpackaging production machine hardware. Furthermore, using substantiallythe entire width of production materials greatly reduces, and canpotentially eliminate, waste of production material. Producing multipletemplates side-by-side is discussed in greater detail in reference to atleast FIGS. 8 and 9.

In the foregoing description, particular mention is made of the size offanfold or other packaging material and/or the dimensions of packagingand/or packaging templates. It should be appreciated that thesedimensions are merely exemplary and are provided to illustrate examplecircumstances in which different variations of a design may be used. Inpackaging design table 301, no dimensions are included for design groups302, main designs 304, or packaging designs 306. While this is merelyoptional, the exclusion of dimensions may allow for a broader range ofpackaging to be considered.

For example, instead of defining a design group for each product size oreach possible packaging size, a definition similar to that in packagingdesign table is more robust and allows product types to be assigned foreach design group 302. Each main design 304 and packaging designsub-group 306 may have a formula for calculating the size of thepackaging template such that a wide range of packaging sizes may beevaluated. Moreover, in some embodiments, one design group may be withinthe hierarchy of another design group. For instance, by selecting onedesign group, one or more other design groups and the main and/orpackaging designs 304, 306 therein may also be considered.

In some embodiments, a user or computer system assigns values forrestrictions 308 for a design group. Method 600 includes an act ofassigning restrictions/constraints (act 603). In packaging design table301, main designs 304 or packaging designs 306 can assign restrictionsand/or constraints (e.g., restrictions 308). For example, a packagingdesign be assigned a size restriction (e.g., maximum dimension must beless than 34 inches). In this particular example, a packaging design mayallow for any dimension to be up to a specified value. If the dimensionexceeds the specified value, there is a possibility that the templatemay not be producible by a desired packaging production machine, that itwill be produced with undesired crease lines, or have some otherfeature, or a combination thereof.

Any type of constraint or restriction can be assigned. For example,absolute size or dimensional restrictions may be applied, relative sizeor dimensional restrictions may be applied (e.g., length to width ratiomust be less than 7:1). Restrictions or constraints may limit or requirea particular packaging production machine be used to produce the design,or that a particular quality of fanfold material be used. Of courseother considerations can be used in identifying restrictions orconstraints. Thus, a restriction or constraint may be used to specifyconditions that, when existing, exclude the particular design fromfurther consideration or use.

In some embodiments, a user or computer system assigns a value forpreference score 311 or for other priorities or costs for a designgroup. Method 600 includes an act of assigningpreferences/priorities/costs (act 604). Preferences or priorities may beassigned in any of a number of different categories. For example, inpackaging design table 301, preferences or priorities may be assigned todesign features 310. Example design features that may be used in settingpreferences, priorities, costs, and the like include aestheticappearance, labor time, production capabilities, assembly/closingmaterial costs, protective capabilities, or other preferences, orcombinations thereof.

One or more (possibly all) combinations of values for design relatedfeatures 310 can be weighted. Values can be weighted and assignedautomatically, or can be assigned by an engineer or other user,operator, or person knowledgeable of the system described herein. Forexample, each different design feature may be weighed differently. If aparticular design group 302 is likely to be used with fragile or heavyobjects, the protective abilities of the box may be particularlyimportant. On the other hand, if a design group 302 is to be used forexpensive products or high-end customers, aesthetic appearance may beparticularly important. For high volume products, the labor time,production capabilities, assembly material costs, and the like can bevalued highly.

Accordingly, each design group 302 can be considered by weighting thedifferent design-related features 310 in any number of differentmanners. Moreover, the different design groups 302 can have differenttypes of main designs 304 and packaging designs 306 considered. Forexample, some design groups 302 may not consider boxes with integralcorner protectors (e.g., for products that do not need any additionalprotection or which are oddly shaped), while only some design groups 302may consider templates that are produced in two or more separate parts(e.g., a design group 302 for large products). Thus, each design group302 may be customized not only in the manner in which the features 310are evaluated and weighed, but in what main designs 304 and/or packagingdesigns 306 are included as options within the particular design group302.

A number of different design features 310 and a preference score 311 areexpressly depicted in packaging design table 301. Some packaging designsmay not be assigned a value for each of design features 310 and/or forpreference score 311. In some embodiments, none of design features 310are assigned values. Thus, the value for preference score 311 may be asingle value assigned to a particular design. The value for preferencescore 311 can be based on a particular combination of design relatedfeatures deemed important for the design group. The preference value maybe a numerical value (e.g., on a scale of 0 to 100), a letter value(e.g., a value between A and F), a cost value (e.g., an associated costto produce the box based on the design factors 310), or any other typeof value, or a combination thereof.

Method 600 includes an act of setting up additional information (act605). For example, referring again to FIGS. 5A and 5B, packagingmaterials table 501 and machine data table 502 can also be set up.Packaging materials table 501 can be set up to describe aspects of theone or more packaging materials that are available within productionarchitecture 100. For example, packaging materials table 501 describesaspects of packaging materials such as the widths of fanfold productionmaterials that are available, the available quantities of such fanfoldmaterials, and the cost of each type of material. Machine data table 502can be setup to describe aspects of one or more packaging productionmachines that are available within production architecture 100. Forexample, machine data table 502 describes aspects of packagingproduction machines such as cost per second to operate (operation cost)and access to different packaging material sizes.

Embodiments of the invention include a real-time design optimizationsystem that uses the available information to select or identify one ormore optimal packaging designs. Based on design information, packagingmaterial information, and packaging production machine information, adesign for a packaging product can be selected. The real-time designoptimization system can also consider further user entered job specificinformation (e.g., from an operator) to facilitate design selection.

Method 600 includes an act of inputting job specific information (act606). For example, turning briefly again to FIG. 4, the real-time designoptimization system can consider job specific information enteredthrough user-interface 401. Job specific information can indicate a jobfor a single box, multiple identical boxes, or multiple different boxes.When entering information at user-interface 401, an operator or otheruser may input information such as the design group that is to be used.As noted above, each design group may include different types ofpackaging designs.

Additionally, or alternatively, each design group may weight differentdesign-related features in a different manner. For instance, as depictedin user-interface 401 one or more design groups 302 identified alongwith a basic description of that design group. The description mayinclude size, weight, product category, or other information that anoperator may use to identify what design group is to be considered. Insome embodiments, multiple design groups are selected by the user forconsideration.

Method 600 includes an act of updating information (act 607). Forexample, user-interface 401 depicts various fields in which the user mayenter dimensional information. An operator may know, for example, that adesired box has dimensions A, B and C, in which case such dimensions maybe entered into the appropriate fields of user-interface 401. Thedimensional information may be entered in a number of different units aswell. For example, the system may request the dimensions in inches,feet, centimeters, meters, or other dimensions. The user may also beable to specify the units in which the specified value is input. Forinstance, a drop-down box may allow the user to specify that the unitsare provided in inches rather than centimeters.

Other information can also be input. For example, at user-interface 401,an operator or other user can enter information about productionconditions. If an incident has occurred that has slowed or stoppedproduction, this condition may be entered. A check box or other inputmechanism can be used to indicate that production has stopped or slowed.User-interface 401 can also be used to input a time cost. The time costcan be increased as production stops or slows. As described, the timecost can be used to evaluate production time. For high production costs,a real-time optimization system can look for solutions that reduceproduction time. Additional information may also be input. For example,additional information about the availability of fanfold or otherproduction materials, identification of production machines that areoffline, or other information, or combinations thereof, may also bespecified.

Method 600 includes an act of identifying approved design solutions (act608). For example, a real time design optimization system can considerdimensional information and other information specified by a user inview of design restrictions to evaluate each main design in a specifieddesign group. Designs that can satisfy user entered information in viewof design restrictions are identified as approved design solutions. Alist of approved solutions can be displayed to a user and/or stored(e.g., in data store 106).

A real time design optimization system can evaluate the restrictions orother constraints specified for any design in the design group. If, forexample, a design has a restriction that is not satisfied (e.g., sizerestriction, dimensional restriction, packaging production machinelimitation, material quality limitation, etc.), that design can beexcluded from a list of available possible solutions. Other restrictionsor constraints can also be evaluated. For example, additionalrestrictions may relate to availability of fanfold or productionmachines (e.g., can only be produced on a particular machine), timecosts (e.g., only use if the time cost is below a certain value orbetween certain values), or based on other factors, or any combinationof the foregoing.

Method 600 includes an act of calculating material cost (act 609). Forexample, a real time design optimization system can identify fanfoldwidths that are available at packaging production machines (e.g., atpackaging production machine 102). For each approved solution, the realtime design optimization system can calculate the amount of fanfoldmaterial used to produce the design. The amount of fanfold material usedcan be based not solely on the footprint of the packaging template, buton the overall usage of fanfold material based on the fanfold width.

Accordingly, a packaging template measuring 50 inches wide by 30 incheslong may have an area of 1500 in². If, however, the packaging templateis produced from fanfold that measures 60 inches wide, the overallmaterial usage may be 1800 in². A rotated version of the same designcould potentially be produced from fanfold measuring 32 inches wide,such that the rotated version may be produced using approximately 1600in² of fanfold material. Thus, calculating the material cost may alsoinclude considering the available materials available to the packagingproduction machines, including their different sizes, qualities, andquantities.

With the fanfold material usage known, a cost can be calculated. Forexample, for fanfold material having a cost of $0.03 ft2, the overallcost of 1600 in² of fanfold material may be about $0.33. The overallcost of 1800 in² of fanfold material may then be about $0.38.Accordingly, based on the different widths of fanfold materialavailable, and the various main designs 304 and sub-designs 306 within adesign group 302, a number of different costs may be obtained forfanfold material. Furthermore, different fanfold material widths mayhave different associated costs. For instance, quality of fanfold mayvary such that the cost of one fanfold material is higher relative toanother (e.g., cost per square foot varies for different fanfold). Inother embodiments, the producer may want to close-out a particular widthof fanfold so that a lower cost may be assigned to such fanfoldmaterial.

The amount of material used to produce a design—and thus the materialcost for a box or other package—can be a factor in determining what boxto produce. However, other factors can also be considered. For example,as described, each main or packaging design 304, 306 within a designgroup 302 may have particular values or preferences assigned based ondesign-related features 310. Accordingly, a real time designoptimization system can consider a number of the design-related featuresbefore identifying an optimal design.

For example, a box template produced with lower material cost maynonetheless have costly assembly/closing materials, or a high labor costassociated with assembly the box. These and other factors can outweighthe lower material cost, resulting in selection of an alternativedesign. In other embodiments, the low material cost design may also havepoor aesthetic or protective capabilities. As a result, when a real timedesign optimization system evaluates the various aspects, a design groupwith a high weight or preference to aesthetic qualities and/orprotective qualities may also outweigh the lower relative material costof one design over another.

Method 600 includes an act of assigning preferences scores (act 610).For example, a real time design optimization system can assign apreference score for each approved solution from act 608. Method 600includes an act of combining preference score and material cost (act611). For example, a real time design optimization system can combinecalculated material costs from act 609 with assign preference scoresfrom act 610.

Any desired algorithm for combining a preference score and materialcost, or otherwise producing the score value may be used. For example, aset of approved design options may include the following values andmaterial cost values as depicted in Table 1:

TABLE 1 Preference Material Value Cost Design 1 83 $0.36 Design 2 44$0.24 Design 3 60 $0.28 Design 4 85 $0.27 Design 5 92 $0.34 Design 6 68$0.30 Design 7 71 $0.30 Design 8 56 $0.28 Design 9 75 $0.35 Design 10 77$0.33

The Preference Values and Material Cost values for each design may thenbe combined in a manner that produces an overall score. According to oneexample, the preference and material cost values may be normalized andgiven equal weight in computing the preference score. For example, thepreference value for each design may be normalized by dividing eachvalue by the maximum Preference Value. Thus, Design 5 may obtain anormalized Preference value of 1.00.

The Material Cost values may also be normalized. For example, thematerial cost value for each design may be normalized by dividing eachvalue by the minimum Material Cost value. Thus, Design 2 may obtain anormalized Material Cost value of 1.00. If an assumption is made that avalue having twice the cost as Design 2 has a normalized value of 0.00,then the normalized value may be obtained by the equation:

${NMCV} = {{{MCV}*\frac{- 1}{MMCV}} - 2}$

where:

NMCV is the Normalized Minimum Material Cost Value;

MCV is the Material Cost Value; and

MMCV is the Minimum Material Cost Value.

The normalized preference values and material cost values can thenweighted equally and summed. With the designs sorted by Score ValueTable 2 depicts score values for the designs form Table 1:

TABLE 2 Normalized Normalized Score Preference Value Material Cost ValueDesign 4 0.924 0.875 1.799 Design 5 1.000 0.583 1.583 Design 7 0.7720.750 1.522 Design 6 0.739 0.750 1.489 Design 3 0.652 0.833 1.486 Design2 0.478 1.000 1.478 Design 10 0.837 0.625 1.462 Design 8 0.609 0.8331.442 Design 1 0.902 0.500 1.402 Design 9 0.815 0.542 1.357

Accordingly, in Table 2, it can be seen that Design 4 has the highestScore Value according to the particular combination of material costsand preference values assigned in the selected Design Group. The usedpreference values may be based on one or more algorithms orconsiderations that place different weights, preferences or prioritieson different design features 310. Moreover, the described normalizationmethod is merely one mechanism for computing a score value based on apreference value and a material cost.

In other embodiments, the preference and/or material costs may benormalized, weighted, or otherwise used, or a combination of theforegoing, in other manners. For example, a preference value can betranslated into a direct cost that may be added to the material costsuch that the material cost need not be normalized. In anotherembodiment, the material cost is normalized based on a differencebetween the maximum and minimum costs, rather than on the minimummaterial cost. In still other embodiments, different calculations,algorithms, normalizations, and/or other factors, or a combinationthereof may be considered.

Method 600 includes an act of identifying top solutions (act 612). Forexample, a real time design optimization system can identify topsolutions from Table 2. Thus, it may be that the score values from Table2 are used to limit the number of solutions for additional or finalconsideration. Further, a design group 302 may include a number ofdifferent main designs 304 and a number of packaging designs 306 assub-designs within a main design 302. Indeed, there may easily bedozens, if not hundreds or thousands, of possible options that may bescored and considered. Thus, the score value is used to identify a topset of solutions, such as, for example, the top ten solutions. FromTable 2, the top seven solutions can be identified, although more orfewer than seven or ten solutions may also be identified as the topsolutions.

Whether or not a number of top solutions are identified, a real timedesign optimization system may then choose one design to use forproducing a packaging product. In some embodiments, the chosen design isselected based exclusively on the score value. In other embodiments, thetop solutions may be provided to an operator via a user interface toallow the user to select the chosen design. The user interface can alsoindicate the relative score values and potentially the calculations orbasis of the score value calculation.

In further embodiments, the identified top solutions are furtherprocessed to further refine the list of top solutions. For example, thetop solutions can further be evaluated based on production time. Asnoted herein, production time may be particularly important in someindustries and/or at certain production times. During a busy productionsystem, packaging production machines may create a bottleneck such thatreducing the production time will allow greater throughput. In othertimes, a production slow-down or stoppage may also create a productionbacklog that increases the importance of production time. In still othercases, production machines may have excess capacity available such thatproduction time is of little or no concern.

Method 600 includes an act of simulating production time (act 613). Forexample, a real time design optimization system can simulate productiontime for top solutions identified in act 612. In some embodiments,simulating production times is based on knowledge the real-time designoptimization system maintains about the one or more production machines.Production time can be simulated for top solutions or all solutionsbased on resource requirements for corresponding calculations.

Depicted in Table 3, the top seven of the previously identified tendesigns have been selected for processing by simulating the productiontime. While the following table includes the production time, anassociated cost may additionally or alternatively be used. For example,if different machines are used and have different associated costs, theproduction value may be a cost value associated with the particularmachine on which the design template will be produced.

TABLE 3 Normalized Normalized Production Preference Value Material CostTime Design 4 0.924 0.875 3.1 Design 5 1.000 0.583 2.75 Design 7 0.7720.750 2.45 Design 6 0.739 0.750 2.77 Design 3 0.652 0.833 2.9 Design 20.478 1.000 2.8 Design 10 0.837 0.625 2.55

Method 600 includes an act of combining production time with preferencescore and material cost (act 614). For example, a real time designoptimization system can combine production times from act 613 withpreference scores from act 610 and material costs from act 609.Production time can be normalized in a manner similar to that shownabove for normalizing the material cost (i.e., such that Design 7 has avalue of 1.00 and a design taking twice as long to produce would have anormalized value of 0.00). Table 4 depicts Total scores for the Topseven designs from Table 1. Total score can weight preference value,material costs, and production time equally.

TABLE 4 Normalized Normalized Production TOTAL Preference Value MaterialCost Time (s) SCORE Design 4 0.924 0.875 0.735 2.534 Design 7 0.8370.625 1.000 2.462 Design 5 1.000 0.583 0.878 2.461 Design 10 0.478 1.0000.959 2.437 Design 6 0.772 0.750 0.869 2.391 Design 2 0.652 0.833 0.8572.343 Design 3 0.739 0.750 0.816 2.305

As shown Table 4, Design 4 has been given the highest overall score,while of the top designs, Design 3 has the lowest overall score. Thevalues obtained for the score can be based on a sum of normalizedvalues; however, average scores, cost values, weighted sums, or otheralgorithms or manners for computing a total score may be used.

Method 600 includes an act of eliminating doublets (act 615). Forexample, a real time design optimization system can eliminate doubletsfrom the designs in Table 4. The real time design optimization systemcan further refine and/or process scores and designs to identify thosedesigns that are at least significantly similar and potentially alike inall significant aspects. For example, if any designs have identical orvery similar Preference Values, Material Costs, and/or Production Times,all but one of such similar designs (i.e., doublets) can be eliminated.Additionally, or alternatively, consideration of doublets forelimination may include evaluating other aspects, including the type ofdesign (e.g., RSC full flap, integrated corner protectors, bottom lid,etc.) or other aspects.

Method 600 includes an act of identifying top solutions (act 616). Forexample, a real time design optimization system can identify the topsolutions from Table 4 (either with or without doublet elimination). Forexample, the highest scoring design may be selected and transferred forproduction. Alternately, a top number of designs (e.g., top 5 designs)can be selected. If a top number of designs is selected, any number maybe used. For example, more or fewer than 5 designs may be selected asthe top number of designs.

Method 600 includes an act of selecting a design for production (act617). For example, a real time design optimization system can select adesign for production at packaging production machine 102. In someembodiments, a real time design optimization system automaticallytransfers the top scored design for production. In other embodiments,however, an operator may be notified of the top number of designs, oroptionally of all or some other number of designs. For example,referring to FIG. 7, user-interface 701 gives an operator or other userthe option to choose a design from among the top designs.

If the top three designs are provided to the operator, the operator canchoose to do nothing, thereby resulting in a top scored design beingtransferred for production. The operator may actively select that theoperator is not overriding the choice, or after a specified time withoutoperator selection, the top design may be transferred to the packagingproduction machine for operation. Alternatively, if the operator desiresa different design to be transferred for production, the operator mayselect one of the other options (e.g., the designs ranked as the topsecond through fifth) designs. In still another alternative, theoperator may indicate that no solution is desired and the operator canselect a different available design (e.g., one of the previously scoredbut not top designs).

As further depicted in user-interface 701, pictures of the assembledbox, box template, or some other image may be used to graphicallyillustrate the various available boxes. In other embodiments, boxes areidentified by information or name only. Accordingly, it should beappreciated that it is not necessary that an image of a box or templatebe provided to the operator.

Accordingly, embodiments of the invention include automaticallyoptimizing production of packaging products based on stored and/orreal-time information. In some embodiments, a request for a packagingproduct is received and a real-time design optimization system accessesinformation about one or more design groups. The one or more designgroups include multiple design options. The multiple design options arescored based on stored and/or real-time criteria. Based on the score,one or more top designs are identified for production and/or selectionby an operator of the system.

As was mentioned previously, embodiments of the invention also includeproducing multiple templates (e.g., box templates) side-by-side (ortiled) within source production material. That is, the productionarchitecture 100 can facilitate production of two or more templatessubstantially in parallel on each production track (e.g., productiontracks 102A, 102B, and 102C). Tiling templates during production can beperformed a part of automatically optimizing production of packagingproducts based on stored and/or real-time information, as discussedabove. For example, packaging design table 301, or a separate datastructure, can contain information about possible combinations andarrangements of design groups 302, main designs 304, and/or packagingdesigns 306 that can be tiled together. This information can be used byoptimization module 112 when selecting suitable packaging designs.Alternatively, tiling templates during production can be performed as aseparate process.

FIG. 8 illustrates an embodiment of a production track 800 that isconfigured to produce tiled templates within source production material,in accordance with one or more embodiments. Production track 800 mayrepresent one or more of production tracks 102A, 102B, 102C of FIG. 1,for example.

As depicted, production track 800 includes material loading tray 802,template production device 804 (e.g., a configurable cutting or stampingdevice), and material exit tray 806. Production track 800 is configuredto receive source packaging material 808 a at material loading tray 802and to feed the source packaging material 808 a into template productiondevice 804. Source packaging material 808 a is typically fanfold orrolled corrugated board, but could also comprise other packagingmaterials, such as plastic, vinyl, or other materials suitable forcreating packaging products.

Template production device 804 is configured to follow instructions(e.g., production instructions 114 as generated by computer system 104)to stamp and/or cut templates for packaging products (e.g., boxes) intothe source packaging material 808 a. For example, production track 800is depicted as having output, onto material exit tray 806, processedpackaging material 808 b that includes two packaging templates 809 a and809 b in a tiled or side-by-side configuration. In doing so, productiontrack 800 has thus produced, in the illustrated embodiment, two boxtemplates in parallel, while greatly reducing the amount of waste thatwould have been generated when producing a single box template of thesame size.

It should be understood, for purposes of the present invention, that themechanism for loading source packaging material 808 a into productiontrack 800, and for unloading processed packaging material 808 b fromproduction track 800 can be accomplished in ways other than with theillustrated material loading tray 802 and material exit tray 806. Forexample, one or more embodiments make use of conveyor platforms, or evenoperate without the use of trays or platforms.

Although production track 800 is depicted as having produced twoidentical tiled templates 809 a and 809 b, embodiments of the inventioncan produce any variety of different template types, shapes, sizes, andorientations, with these different templates being configured in anyappropriate tiled configuration. Thus, production track 800 can producea plurality of templates, each having differing box types, shapes, andsizes in a parallel, tiled manner. Furthermore, although productiontrack 800 is depicted as having produced two templates 809 a and 809 bin a parallel, tiled manner, production track 800 could produce anynumber of templates in a parallel, tiled manner (e.g., three or more).

Production track 800 is capable of producing templates for boxes havingany number of characteristics. As mentioned, different types of boxes orother packaging may be used or desirable for different packagingprojects. Box size and additional features includes in the boxes canvary based on what is being enclosed within the box. Enclosing a heavyor fragile object may, for example, dictate that a box of a certain typeof material be used, or that a box that has improved protection orconstruction characteristics (e.g., glue flap, integral cornerprotectors, full size flaps, nunatabs, etc.) be used. Production track800 can be configured to produce boxes having these features in aparallel, tiled manner. For example, production track 800 can produceboxes having glue flaps, and when doing so tiling the boxes can involvetiling the box templates so that edges on glue flaps of a first box arecollinear with edges on glue flaps of a second box. Furthermore,production track 800 can produce paired boxes having connected bynunatabs. For example, the nunatabs may be positioned proximate to theglue strips.

FIG. 9 details a flowchart of an exemplary method 900 for tilingproduction for a pair of boxes. Method 900 will be described withrespect to the components and data of computer architecture 100 andproduction track 800.

Method 900 includes an act of accessing item data identifying aplurality of items that are to be packaged (act 901). For example,computer system 104 can receive information, either though user input orthrough data in a data store (e.g., data store 106) indicating two ormore items that are to be packaged. The information can include, forexample, object types, object dimensions, durability characteristics,and the like. In some embodiments, act 901 can include accessing a queueof items that are to be packaged, such as a first-in-first-out (FIFO)queue, a last-in-first-out (LIFO) stack, etc.

Method 900 also includes an act of determining packaging requirementsfor each of the plurality of items (act 902). For example, computersystem 104 can utilize embodiments previously described to automatically(or substantially automatically) determine packaging requirements foreach of the plurality of items. Determining packaging requirements caninclude selection of potential packaging designs and potential packagingmaterials using information in data store 106. Thus, where appropriate,computer system 104 can also access one or more of packaging materialstable 501 or machine data table 502. Referring to FIG. 5A, for example,packaging materials table 501 indicates packaging materials that areavailable within production architecture 100, some of which may beavailable at packaging production machine 102. For example, packagingmaterials table 501 includes information such as name, type, width,thickness, quantity, and cost of packaging material. Furthermore,referring to FIG. 5B, machine data table 502 includes information aboutpackaging production machines in production architecture 100. Forexample, machine data table 502 includes information about packagingproduction machines, including names, associated operational costs(e.g., relative cost for each second that is required to produce apackaging product), availability of different packaging materials at themachines, etc. As such, act 902 can, in one or more embodiments, utilizeone or more acts described previously in connection with at least theFIG. 2 (i.e., method 200 for optimizing production of packagingproducts) and/or FIG. 6 (i.e., method 600 for selecting a design for apackaging product) when determining packaging requirements for each ofthe plurality of items.

Alternatively, computer system 104 can prompt a user for express inputproviding packaging requirements, consult a database that maps itemtypes with packaging requirements, or use any other appropriatemechanism for determining packaging requirements.

Method 900 includes an act of selecting a pair of box sizes for tiledproduction at a packaging production machine, the pair of box sizesincluding a first box size for packaging a first one or more items inthe plurality of items and including a second box size for packaging asecond one or more items in the plurality of items, the pair of boxsizes satisfying the packaging requirements for the first one or moreitems and second one or more items, the packaging production machineselected from among the one or more packaging production machines (act903). For example, optimization module 112 at computer system 104 candetermine, based on the packaging requirements, optimized box sizes foreach of the plurality of items. The optimized box sizes may be chosenbased on one or more of the suitability of each box size for each item,the ability of the box sizes to be tiled together, the type and/ordimensions of available production machines, cost considerations, userpreference, or any other factor described in this disclosure inconnection with optimizing production of packaging products. It will beappreciated that selecting the pair of box sizes can involve selectingthe same box size for each item, or selecting different box sizes fordifferent items. In some circumstances, different box sizes may beselected even for identical items (e.g., based factors such asproduction availability, the ability of box sizes to tile, etc.)

In connection with selecting a pair of box sizes and selecting apackaging production machine from among the one or more packagingproduction machines, act 903 includes an act of, at a specified time,collectively analyzing (a) analyzing (a) the packaging requirements foreach of the plurality of items, (b) the packing system characteristics,and (c) the packaging machine characteristics for each of the one ormore packaging production machines (act 904). For example, act 904 caninvolve an analysis of packaging production machine 102 (as well as anyother production machines) and an analysis of any production tracks atthose machines, in view of the packaging requirements. The analysis caninclude taking into consideration the current and future workloads ofthe packaging production machine(s), the cost of operating each machine,source material availability at each machine, maximum width of eachproduction track, etc.

Act 903 also includes an act of determining how to allocate boxproduction to the one or more packaging production machines for a periodof time based on the collective analysis (act 905). For example, basedon the foregoing analysis of act 904 it can be determined that, givencurrent machine and materials availability, the particular packagingrequirements for the items are best met by producing the first andsecond boxes in a tiling arrangement at a particular production track ata particular production machine during a given period of time.Determining how to allocate box production can also include comparingdimensions of box templates or blanks that are to be tiled, and ensuringthat the dimensions for each template/blank are within specifiedthresholds of one another. If the dimensions are not within specifiedthresholds of one another, act 905 can include modifying the design ofone or more of the box templates or blanks so that they fall within thespecified thresholds.

Act 905 includes an act of matching the pair of box sizes to thepackaging production machine based on the collective analysis (act 906).For example, the pair of box sizes can be matched to packagingproduction machine 102. Act 906 can include determining that packagingmaterial loaded at the production machine is large enough to tileproduction of the requested boxes. Act 906 can also include determiningany waste that may result from producing the part of boxes, and ensuringthat the waste is within acceptable tolerances. Act 906 can also includedetermining that the production machine can handle the required load.

Method 900 also includes an act of generating box productioninstructions in response to the selection, the box productioninstructions indicating how to tile production of a box of the first boxsize with a box of the second box size at the packaging productionmachine (act 907). For example, computer system 104 can generateproduction instructions 114 which instruct a production track (e.g., oneor production track 102A, 102B or 102C) at production machine 102 to useraw materials to create a plurality of tiled packaging products.

In addition, method 900 also includes an act of sending the boxproduction instructions to the packaging production machine (act 908).For example, computer system 104 can send production instructions 114 toproduction machine 102 to generate the boxes in a tiled and parallelmanner.

While the method 900 has been described in the context of producing apair of boxes in parallel, method 900 is also applicable for producingany number of boxes in any tiled configuration. For example, method 900may include tiling three box sizes together, four box sizes together,five box sizes together, etc.

When four box sizes are tiled, method 900 may include selecting a secondpair of box sizes for tiled production, including a third box size forpackaging a third one or more items in the plurality of items and afourth box size for packaging a fourth one or more items in theplurality of items. Then, based on further analysis, the third andfourth box sizes can be tiled with other box sizes in any appropriateconfiguration. In some embodiments, for example, one or both of thethird or fourth boxes may be produced in parallel with one or both ofthe first or second boxes, at least in part.

Accordingly, embodiments of the invention also include producing boxtemplates or blanks in a parallel, tiled manner. Doing so can improvethe speed and efficiency with which boxes are created, can make optimaluse of production hardware, and can help to reduce waste.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the invention is, therefore, indicatedby the appended claims rather than by the foregoing description. Allchanges which come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

What is claimed:
 1. At an electronic packaging system, the electronicpackaging system having packaging system characteristics, some ofpackaging system characteristics varying over time, the electronicpackaging system including one or more packaging production machines,each packaging production machine having packaging machinecharacteristics, some of the packaging machine characteristics varyingover time, each packaging production machine loaded with packagingmaterial for producing boxes, a method for tiling production for a pairof boxes, the method comprising: an act of accessing item dataidentifying a plurality of items that are to be packaged; an act ofdetermining packaging requirements for each of the plurality of items;an act of selecting a pair of box sizes for tiled production at apackaging production machine, the pair of box sizes including a firstbox size for packaging a first one or more items in the plurality ofitems and including a second box size for packaging a second one or moreitems in the plurality of items, the pair of box sizes satisfying thepackaging requirements for the first one or more items and second one ormore items, the packaging production machine selected from among the oneor more packaging production machines, including: an act of, at aspecified time, collectively analyzing (a) the packaging requirementsfor each of the plurality of items, (b) the packing systemcharacteristics, and (c) the packaging machine characteristics for eachof the one or more packaging production machines; and an act ofdetermining how to allocate box production to the one or more packagingproduction machines for a period of time based on the collectiveanalysis, including: an act of matching the pair of box sizes to thepackaging production machine based on the collective analysis; an act ofgenerating box production instructions in response to the selection, thebox production instructions indicating how to tile production of a boxof the first box size with a box of the second box size at the packagingproduction machine; and an act of sending the box productioninstructions to the packaging production machine.
 2. The method asrecited in claim 1, wherein the act of selecting a pair of box sizes fortiled production at a packaging production machine comprises an act ofselecting a pair of box sizes, wherein the first box size and the secondbox size are of the same box type.
 3. The method as recited in claim 1,wherein the act of selecting a pair of box sizes for tiled production ata packaging production machine comprises an act of selecting a pair ofbox sizes, wherein the first box size and the second box size are of thesame box type and wherein the box size and the second box size are thesame size.
 4. The method as recited in claim 1, wherein the act ofselecting a pair of box sizes for tiled production at a packagingproduction machine comprises an act of selecting a pair of box sizes,wherein the first box size and the second box size are of different boxtypes.
 5. The method as recited in claim 1, wherein the act of sendingbox production instructions to the packaging production machinecomprises an act of sending box production instructions to include glueflaps on the first box and on the second box.
 6. The method as recitedin claim 5, wherein the act of sending box production instructions toinclude glue flaps on the first box and on the second box comprisessending box production instructions for producing the first box and thesecond box side-by-side, the edges of the glue flaps on the first boxbeing collinear with the edges of the glue flaps on the second box. 7.The method as recited in claim 1, wherein the act of determining how toallocate box production to the one or more packaging production machinesfor a period of time comprises: an act of determining a length of afirst packaging blank for the first box and a length of a secondpackaging blank for the second box; and an act of calculating that thelength of the first packaging blank and the length of the secondpackaging blank are within a specified threshold of one another.
 8. Themethod as recited in claim 1, wherein the act of determining how toallocate box production to the one or more packaging production machinesfor a period of time comprises: an act of determining a length of afirst packaging blank for the first box and a length of a secondpackaging blank for the second box; an act of calculating that thelength of the first packaging blank and the length of the secondpackaging blank differ by more than a specified threshold; and an act ofmodifying the design of at least one of the first and second boxes sothat the length of the first packaging blank and the length of thesecond packaging blank are within the specified threshold of oneanother.
 9. The method as recited in claim 1, wherein the act ofmatching the pair of box sizes to the packaging production machine basedon the collective analysis comprises: an act of determining that thepackaging material loaded at the packaging production machine is ofsufficient size to tile production of the pair of boxes; an act ofdetermining that waste resulting from tiling production of the pair ofboxes at the packaging production machine is acceptable; and an act ofdetermining that production load for the packaging production machinecan handle tiling production of the pair of boxes.
 10. The method asrecited in claim 1, wherein the act of sending box productioninstructions to the packaging production machine comprises an act ofsending box production instructions to place one or more nunatabs at aninterface between the first box and the second box.
 11. The method asrecited in claim 10, wherein sending box production instructions toplace one or more nunatabs at an interface between the first box and thesecond box comprises an act of sending box production instructions toplace nunatabs proximate to a glue strip.
 12. The method as recited inclaim 1, wherein the act of accessing item data identifying a pluralityof items that are to be packaged comprises an act of accessing one of astream of item data or a batch of item data.
 13. The method as recitedin claim 1, further comprising: an act of selecting a second pair of boxsizes for tiled production at another packaging production machine, thesecond pair of box sizes including a third box size for packaging athird one or more items in the plurality of items and including a fourthbox size for packaging a fourth one or more items in the plurality ofitems, the second pair of box sizes satisfying packaging requirementsfor the third one or more items and the fourth one or more items, theother packaging production machine selected from among the one or morepackaging production machines, including: an act of, at a secondspecified time, further analyzing (a) the packaging requirements foreach of the plurality of items, (b) the packing system characteristics,and (c) the packaging machine characteristics for each of the one ormore packaging production machines; and an act of determining how toallocate box production to the one or more packaging production machinesfor a second period of time based on the further analysis, including: anact of matching the second pair of box sizes to the other packagingproduction machine based on the further analysis; an act of generatingfurther box production instructions in response to the selection of thesecond pair, the further box production instructions indicating how totile production of a box of the third box size with a box of the fourthbox size at the other packaging production machine; and an act ofsending the box production instructions to the other packagingproduction machine.
 14. The method as recited in claim 14, wherein theother packaging production machine is the packaging production machine.15. An electronic packaging system, the electronic packaging systemhaving packaging system characteristics, some of packaging systemcharacteristics varying over time, the electronic packaging systemincluding: one or more packaging production machines, each packagingproduction machine having packaging machine characteristics, some of thepackaging machine characteristics varying over time, each packagingproduction machine loaded with packaging material for producing boxes;one or more computer storage devices having stored thereoncomputer-executable instructions representing a production engine,wherein the production engine is configured to: communicate with the oneor more packaging production machines; access item data identifying aplurality of items that are to be packaged; determine packagingrequirements for each of the plurality of items; select a pair of boxsizes for tiled production at a packaging production machine, the pairof box sizes including a first box size for packaging a first one ormore items in the plurality of items and including a second box size forpackaging a second one or more items in the plurality of items, the pairof box sizes satisfying the packaging requirements for the first one ormore items and the second items one or more items, the packagingproduction machine selected from among the one or more packagingproduction machines, including: at a specified time, collectivelyanalyzing (a) the packaging requirements for each of the plurality ofitems, (b) the packing system characteristics, and (c) the packagingmachine characteristics for each of the one or more packaging productionmachines; and determining how to allocate box production to the one ormore packaging production machines for a period of time based on thecollective analysis, including: matching the pair of box sizes to thepackaging production machine based on the collective analysis; generatebox production instructions in response to the selection, the boxproduction instructions indicating how to tile production of a box ofthe first box size with a box of the second box size at the packagingproduction machine; and send the box production instructions to thepackaging production machine; and wherein each of the one or morepackaging production machines is configured to: receive box productioninstructions from the production engine; and produce one or more boxesin accordance with the received box production instruction, includingtiling production of a pair of boxes when instructed to do so.
 16. Theelectronic packaging system of claim 16, wherein the production enginebeing configured to access item data identifying a plurality of itemsthat are to be packaged comprises the production engine being configuredto item data identifying a plurality of items that are to be packaged onfirst-in first-out basis.
 17. The electronic packaging system of claim17, wherein the production engine being configured to determine how toallocate box production to the one or more packaging production machinescomprises the production engine being configured to alter the first-infirst-out basis when the collective analysis indicates an efficiencygain is possible if the first-in first-out basis is altered.
 18. At anelectronic packaging system, the electronic packaging system havingpackaging system characteristics, some of packaging systemcharacteristics varying over time, the electronic packaging systemincluding one or more packaging production machines, each packagingproduction machine having packaging machine characteristics, some of thepackaging machine characteristics varying over time, each packagingproduction machine loaded with packaging material for producing boxes, amethod for producing boxes for a plurality of groups of one or moreitems, the method comprising: an act of accessing item data identifyinga plurality of items that are to be packaged; an act of determiningpackaging requirements for each of the plurality of items; an act ofselecting a group of box sizes for tiled production at a packagingproduction machine, the group of box sizes including at least: (a) afirst box size for packaging a first one or more items in the pluralityof items, (b) a second box size for packaging a second one or more itemsin the plurality of items, and (b) a third box size for packaging athird one or more items in the plurality of items, the group of boxsizes satisfying the packaging requirements for the first one or moreitems, the second one or more items, and the third one or more items,the packaging production machine selected from among the one or morepackaging production machines, including: an act of, at a specifiedtime, collectively analyzing (a) the packaging requirements for each ofthe plurality of items, (b) the packing system characteristics, and (c)the packaging machine characteristics for each of the one or morepackaging production machines; and an act of determining how to allocatebox production to the one or more packaging production machines for aperiod of time based on the collective analysis, including: an act ofmatching the group of box sizes to the packaging production machinebased on the collective analysis; an act of generating box productioninstructions in response to the selection, the box productioninstructions indicating how to tile production of a box of the first boxsize, a box of the second box size, and a box of the third size at thepackaging production machine; and an act of sending the box productioninstructions to the packaging production machine.
 19. The method asrecited in claim 19, wherein the act of matching the group of box sizesto the packaging production machine based on the collective analysiscomprises: an act of determining that the packaging material loaded atthe packaging production machine is of sufficient size to tileproduction of the group of boxes; an act of determining that the wasteresulting from tiling production of the group of boxes at the packagingproduction machine is acceptable; and an act of determining that theproduction load for the packaging production machine can handle tilingproduction of the group of boxes.
 20. At an electronic packaging system,the electronic packaging system having packaging system characteristics,some of packaging system characteristics varying over time, theelectronic packaging system including one or more packaging productionmachines, each packaging production machine having packaging machinecharacteristics, some of the packaging machine characteristics varyingover time, each packaging production machine loaded with packagingmaterial for producing boxes, a method for tiling production for aplurality of boxes, the method comprising: an act of accessing item dataidentifying a plurality of items that are to be packaged; an act ofdetermining packaging requirements for each of the plurality of items;an act of determining a first box size for packaging a first one or moreitems in the plurality of items and a second box size for packaging asecond one or more items in the plurality of items, the first and secondbox size for tiled production at a packaging production machine, thefirst and second box sizes satisfying the packaging requirements for thefirst one or more items and second one or more items, the packagingproduction machine selected from among the one or more packagingproduction machines, including: an act of, at a specified time,collectively analyzing (a) the packaging requirements for each of theplurality of items, (b) the packing system characteristics, and (c) thepackaging machine characteristics for each of the one or more packagingproduction machines; and an act of determining how to allocate boxproduction to the one or more packaging production machines for a periodof time based on the collective analysis, including: an act of matchingthe first and second box sizes to the packaging production machine basedon the collective analysis; an act of generating box productioninstructions in response to the selection, the box productioninstructions indicating how to tile production of a box of the first boxsize with a box of the second box size at the packaging productionmachine; and an act of sending the box production instructions to thepackaging production machine.